Spot welding timer



Nov. 5, 1940.

F. H. GULLlKsx-:N 2,220,151

SPOT WELDING TIMER Filed Aug. 3, 1938 #www TORNEY Patented Nov. 5, 1940 UNITED STATES,

PATENT OFFICE SPOT WELDING TIMER Pennsylvania Application August 3, 193s, serial No. 222,802

14 Claims.

My invention relates to control apparatus and has particular relation to apparatus for controlling the supply oi' power to a load requiring discrete precisely timed impulses of current.

The present invention is an out-growth and improvement of the inventions shown and described in an application Serial No. 34,003 filed July 31, 1935, to John W. Dawson, and assigned to the 'Westinghouse Electric & Manufacturing Company, and my copending applications Serial Nos. 221,857 and 221,858, for 4Spot welding timers, both led July 28, 1938, and assigned to the Westinghouse Electric & Manufacturing Company.

The above-mentioned applications relate specifically to timers for resistance spot welding and disclose timing devices oi relatively intricate structure. in accordance with the Dawson application the flow of welding current is controlled by electric discharge valves. The current flow is initiated by a start valve which renders the control valves conductive, and is interrupted by a stop valve which renders them non-conductive. The start and stop valves are connected in series. The timing takes place by permitting the current flow through the start valve to charge a capacitor in the control circuit of' the stop valve. When the capacitor is charged to a predetermined potential difference, the stop valve is rendered conductive and terminates the flow of welding current.

While the start-and-stop valve timing affords precise timing, it has a number of features which involve substantial cost. Since the timing takes place by charging a capacitor in the control circuit of the stop valve, the bias impressed on the stop valve-which the capacitor potential counteracts should be of substantial magnitude and for this reason a relatively large potential source of one type or another in addition to the main supply source is necessary. Moreover, care must be taken that there be no coaction between the capacitor circuit and the start and stop valve circuits and the control valves, since such cor action may render the control valves conductive after they have been rendered non-conductive by the operation of the stop valve. To avoid such counteraction, the source whereby the start and stop valves are supplied must be provided with relatively expensive filters and compensators. Finally, the connection of the control valves, the vstart valve and the stop valve is such that independent biasing sources are required for these elements.

The apparatus disclosed in my above-mentioned (CL Z50-27) applications is somewhat less expensive than that disclosed in the Dawson application, inasmuch as the stop valve is entirely omitted and the timing takes place directly from the capacitor. However, the precision of the operation is here ail'ect- 5 ed by the elimination of the stop valve. For long welding intervals it is essential that the timing capacitor be charged or discharged for a relatively long interval of time. As the capacitor approaches the completely charged condition the 10 rate of change of its potential approaches zero and therefore random changes in the condition of the control valve materially affect the length of time that the capacitor charges or discharges to render the control valve non-conductive. From the above discussion it is seen that it is a desideratum to retain the stop valve in Welding apparatus if this object can possibly be accomplished.

It is accordingly an object of my invention to provide an economical system for precisely timing the iiow of current to a load that requires power in intermittent pulses.

A more specific object of my invention is to provide an economical system incorporating both a stop valve and a start valve for timing the supply of power to a load that requires current in intermittent pulses.

More concisely stated, it is an object of my invention to Aprovide a resistance spot welding system incorporating both a start valve and a stop valve in which precise timing shall be attained while at the same time the number of the high cost elements required in the prior art arrangements shall not be present.

In accordance with my invention the start valve and the stop valve are connected in parallel instead of in series. By reason of this connection the anode-cathode potential required by the two valves together is materially decreased and the stop valve may be biased from the source from which the anode-cathode potential for the valves is supplied. Moreover, since the bias potential for the stop valve is derived from the same source as the anode-cathode potential for'the start and stop valves, the bias potential is compensated automatically for the changes which take place in the source by reason of variations in the impedance of the rectifying equipment. Also the usual lters and compensators necessary to provide fcr the variations which take place by reason of the changes in the load on the source, when the start valve is rendered conductive, are not necessary.

By reason of the parallel connection of the start Valve and the stop valve, it is possible to supply bias potential from the same source for the start valve and the control valve and for the stop valve and the control valve. This, in itself, represents a substantial saving. However, in view of the interconnection between the start valve circuit and the control valve which arises by reason of the use of common bias, it may happen that the timing capacitor may discharge through portions of the circuit to which the control electrode of the control valve is connected. .To avoid such discharge a rectifier is provided in series with the timing capacitor.

The novel features that I consider characteristic of my invention are set 4forth with particularity in the appended claims. The invention itself, however, both as to its organization and its method o' operation, together with additional objects and advantages thereof, will best be understood from the following description of a specific embodiment when read in connection with the accompanying drawing in which the single figure is a diagrammatic View showing an embodiment of my invention.

The apparatus shown in the drawing comprises a welding transformer i across the secondary 3 oi which a pair of welding electrodes 5 are connected. The electrodes 5 are in contact with the material 'l to be welded, and when the transformer i is energized, welding current idows through the material. The primary Q of the transformer i is supplied from the line conduci tors ii and it of a source oi alternating current (not shown) which may be of the ordinary corn1 mercial frequency type, through a pair oi electric discharge valves i5 and il? connected in anti parallel. Each valve is of the immersed-ignition electrode type and comprises an anode i@ o nickel, carbon'or other similar material, a niercury-pool cathode 2i and a high resistance ignition electrode 253 of boron carbide, silicon carbide, or similar material. Current is supplied to the ignition electrodes 253 of each of the main dis charge valves i5 and il through a pair of auxillary discharge valves 22d and 2 which Lshall herein designate as ignition discharge valves. Each ignition valve is of the arc-like type and comprises an anode 29, a hot cathode @i and a control electrode 33, and suitable ionizing medium such as is provided by a noble gas at a low pressure or by mercury vapor.

' The circuit for the left-hand ignition valve te extends from the left-hand line conductor ii through a conductor 35, the primary 9 of the welding transformer i, a conductor i, a conductor 39, the anode 2S and the cathode 3i o the left-hand valve, the ignition electrode 23 and the cathode 2i of the associated main valve it, a conductor ti, a conductor 43 to the right-hand line conductor It. The ignition circuit for the righthand main valve i7 extends from the right-hand line conductor i3 through the conductor d3, the anode 2Q and the cathode 3i of the ignition valve 2i, the ignition electrode 23 and the cathode @i of the associated main valve ii, the conductor 3i, the primary S of the welding transformer i, the conductor 35 to the left-hand line conductor it.

Control potential is supplied to the left-hand ignition valve 25 from a timing system 55. The control circuit for this valve extends from the control electrode 33 through a grid resistor di,

a conductor 39, a biasing capacitor 5i, supplied from the main line conductors il and i3 through a secondary section 53 of the supply transformer 55 and a dry rectier 57i, a conductor 59, a timing aaeaiei resistor 5i, the right-hand windings dit oi a voltage divider 65 to the cathode 3i. The voltage divider t5 is supplied from the main line conductors Ii--it through a suitable iull wave rectifier 6l and a filter 69. The filter may be of a relatively inexpensive type and need incorporate no compensating equipment.

The ignitionl valve 25 is normally maintained non-conductive by the action of the biasing capacitor 5l and the section 63 of the voltage divider 65 connected in its control circuit. The timing system functions to supply a potential between the control electrode 33 and the cathode 3i of the valve which counteracts the biasing potential and renders the valve conductive. Current then flows through the ignition valve 2.5i and the associated ignition electrode 23 and the associated main valve l5 is rendered conductive, transmitting current to the primary Q of the welding transformer i and therefore causing a welding impulse to be supplied to the material The right-hand ignition valve 2l is not provided with a timing system, but is rendered conductive in response to the current ow through the primary 9 of the welding transformer i. For

this purpose a control transformer il is provided. The primary it of the latter is connected in parallel with the primary d of the welding transformer. The secondary its is connected between contrai electrode 33 and the cathode 3i of the ignition valve 2l through a biasing capacitor l?.

When the ow of Ywelding current is initiated the left-hand main valve i5 first carries current during a half cycle during which itsancdewcathfu ode potential is positive. Since the welding load is reactive the current ow continues tc a point at a substantial angle from the point of zero potential in the. subsequent negative half-cycle. When the current flow is eventually discontinued, a substantial potential is impressed between the control electrode @at and the cathode 3i of the right-hand ignition valve 2li. Since the anodecathcde potential of this valve is at the time positive, as is also the anode-cathode potential oi its associated main valve ii, the former is rendered conductive and supplies current through the ignition electrode 23 of the latter, rendering the latter conductive. Current of the opposite polarity to that supplied by the left-hand main valve i5 now flows through the welding transformer i. After the right-hand main valve i'i ceases to conduct the left-hand valve i5 again conducts in the same manner as originally and is again followed. by the right-hand valve. The alternate conduction of current continues until the left-hand ignition valve i5 is reverted to a non-conductive condition by the operation of the timing system d5.

The timing system comprises an electric discharge valve it for initiating the conductivity of the ignition valve 25 and a discharge valve @i for terminating the conductivity. shall designate the former as a start valve and the latter as a stop valve. The start valve i9 and the stop valve 8i are of the arc-like type having anodes 83 and o5, respectively, cathodes Si and at, respectively, and control electrodes @i and S3, respectively, and suitable ionizing media. The control electrode @i of the start valve 'i9 is connected to its cathode 3l through the biasing capacitor 5l which is in circuit with the control electrode 33 and the cathode 3i of the left-hand ignition valve 25, and thus biasing potential is supplied to both the start valve and the ignition valve from the same device. The biasing potential supplied by the capacitor Il is sufficient to maintain the start valve non-conductive. To counteract the biasing potential, a potential ot peaked wave form is provided through a saturable transformer 95, the secondary 01 of which is in series with the biasing capacitor 6| and the control electrode 9| and the cathode 01. The primary 99 of the saturable transformer is supplied from the main line conductors I3 through a rheostat |i. The setting ofthe rheostat determines the angle in the half cycle o! the main supply at which the impulses appear across the secondary 91 of the saturable transformer.

Before the operation of the apparatus is initiated, the anode-cathode circuit of the start valve 19 is open. To start a welding operation a manually operable circuit controller |03 which may be a push button or a foot switch is closed. By the closing of the switch a relay T05 is energized and its upper movable contactor |01 engages a pair of xed contacts |09 to close the anode-cathode circuit through the start valve 19. The latter circuit extends from the positive terminal of the voltage divider 65, through a conductor ||3, the upper contacts |09 closed by movable contactor |01 of the relay |05, the anode 83 and the cathode 81 of the start valve 19, the conductor 59, the timing resistor 6| to the negative terminal ||5 of the voltage divider. At an instant thereafter which is predetermined by the rheostat |0| in series with the primary 99 of the saturable transformer 95, the start valve 19 is rendered conductive and current flows through the timing resistor 6|.

Since the timing resistor is in circuit with the control electrode 33and the cathode 3| of the ignition valve 25, the potential drop across it is superimposed on the normal biasing potential im- 40 pressed in the control circuit of the ignition valve. This potential drop is of such polarity and magnitude as to counteract the biasing potential, and the ignition valve 25 is rendered conductive and causes the associated main valve to 45 be rendered conductive and current to be supn plied to the welding transformer i.

It is to be noted that the potential drop across the resistor may be within practical limits made as large as may be desired. The magnitude of this potential is in practice made so large that the ignition-valve 25 is rendered conductive with precision regardless of fluctuations or changes in potential in the main source.

For the purpose of terminating the supply of welding current at a predetermined time, a timing capacitor ||1 is connected in parallel with the timing resistor 6| through a rheostat |9 and a rectier |2|. The rectifier |2| passes the charging current from the resistor 6| to the capacitor ||1, but restrains the capacitor from discharging through the resistor. The rectiiier is necessary because the timing resistor 6| is connected in the control circuit of the left-hand ignition Valve 25 and if the capacitor were to discharge through it, for example, when the relay |05 is iirst deenergized, but before its contacts have had time to settle, the ignition valve 25 may be rendered conductive and spurious current may be supplied through the material 1.

Before the welding operation is initiated the capacitor ||1 is short circuited by the lower contactor |23 of the relay |05 which is, when the relay is deenergized, in engagement with corresponding xed contacts |25. When the relay |05 is energized the short circuit across the capacitor ||1 is shifted and the capacitor charges with its lower plate |21 positive and its upper plate |29 negative at a. rate predetermined by the rheostat setting.

The stop valve 3l is connected in parallel with the start valve 1| and its anode-cathode circuit is also maintained open by the upper movable contactor |01 of the relay |05 before the operation is initiated. The anode-cathode circuitv for the stop valve extends from the positive terminal o1' the voltage divider 65 through the conductor ||3, the upper terminals |09 closed by movable contactor |01 of the relay |05, the anode 95 and the cathode 39 of the stop valve, a conductor |3| to the intermediate terminal |33 of the voltage divider. The control electrode 93 of the stop valve 8| is connected to the negative terminal ||5 of the voltage divider 65 through the lower contactor |23 of the relay |05 when the relay is deenergized and through the timing capacitor ||1 when the relay is energized. It is seen that in either case the negative potential provided by the right-hand portion 63 of the voltage divider 65 is impressed between the control electrode 93 and the cathode 89 of the stop valve 9|. The spacing of the intermediate terminal |33 from the negative terminal ||5 of the voltage divider is such that the potential between these terminals constitutes a substantial fraction of the order of 1/2 orlA of the total potential impressed across the voltage divider. For example, the total voltage divider potential is in a. system constructed according to my invention of the order of 200 volts and the potential between the intermediate terminal |33 and the negative terminal i5 is of the order of` 100 volts. Initially, the stop valve 8| is therefore maintained non-conductive by` the largo bias potential thus provided. The negative bias potential from the voltage divider 65 is counteracted by the potential of the timing capacitor ii'i. At a time predetermined 'oy the setting of the rheostat i |9 the capacitor is charged to such a potential diierence that the stop valve is rendered conductive. When this occurs, the cathode 89 of the stop valve which is connected to the cathode 3| of the left-hand ignition valve 25 is raised substan" tially to the potential of the positive terminal of the voltage divider 55, since the arc drop in the stop valve is only of the order of 10 to 20 Volts. The cathode 3| of the ignition valve 25 is therefore correspondingly raised` On the other hand, the control electrode 33 of the ignition valve 25 is connected to the negative terminal ||5 of the voltage divider 65 through the biasing capacitor 5| and the timing resistor 6|. The drop in potential across the resistor 6| is, however, insufficient to counteract the increase in potential which occurs by raising the cathode 3| of the positive potential of the voltage divider 65. For this reason, the ignition valve 25, when it becomes non-conductive after initiating the last current puise through its associated main valve I5, remains non-conductive and the flow of welding current is stopped.

It is to be noted that the voltage divider taps ||5 and |33 may be so adjusted that in this case again a substantial variation in the control potential impressed on the ignition valve 25 takes place so that regardless of the changes produced in the anode-cathode potential of the ignition valve by reason of changes in the source potential the ignition valve is rendered non-conductive at a precise instant. Moreover, by the proper adjustment of the taps, it is possible to so arrange the relationship between the timing capacitor charging potential and the voltage divider potential that the capacitor potential counteracts the voltage divider potential in the control circuit of the stop valve @l in the region in which the time rate of variation of the capacitor potential is substantial. The time of current :dow throughV the material to be welded may thusbe adjusted with a high degree of accuracy.

Although I have shown and described certain specific embodiments of my invention, I am fully aware that many modiiications thereof are possible. My invention, therefore, is not to be restricted except insofar as is necessitated by the prior art and by the spirit of the appended claims.

I claim as my invention:

i. Ina system for supplying current for discrete intervals of time to a load from a source of current the combination comprising a iirst electric discharge valve means for controlling the iioW oi current from said source to said load, said valve means requiring biasing means, a second electric discharge valve means cooperative with said iirst electric discharge valve means for initiating the iioW of current from said source to said load, said second electric discharge valve means also requiring biasing means, negative biasing means having a potential drop common to said iirst and second electric discharge means; and -a third electric dischargevalve means cooperative vvith said first electric discharge valve means for interrupting the flow of current from said source to said load a predetermined interval of time after it has been initiated.1

2. Apparatus according to claim l characterized by thr fact that the second and third valve means are in parallel circuit relation with each other.

3. Apparatus according to claim i characterized by a capacitor and meansfor charging said capacitor through the second valve means to measure out the predetermined interval of time, means for connecting said capacitor to the third valve means so that said third means is rendered conductive in response to said capacitor after said capacitor has been charged to a predetermined potential' difference and said charging means including means for preventing any substantial discharge of said capacitor through parts of the apparatus affecting said rst valve means.

4. Apparatus according to claim i characterized by a capacitor and means for charging said capacitor through the second valve means to measure out the predetermined interval of time, means for connecting said capacitor to the third valve means so that said third means is rendered conductive in response to said capacitor after said capacitor has been charged to a predetermined potential diierence and said charging means including a rectifier for preventing any substantial spurious discharge of said capacitor through parts of the apparatus affecting said first valve means.

5. In combination a control electric'discharge valve having a control electrode and a plurality of principal electrodes, a start electric discharge valve having a control electrode and a plurality of principal electrodes, a source of potential having a potential drop common to both said valves connected tc impress a blocking potential .between their respective control electrodes and one of their principal electrodes, means for rendering said start valve conductive, means interconnecting said start valve and the control electrode and a principal electrode of said control valve in such manner that said control valve is rendered conductive in response to said start valve, a stop velectric discharge valve having av control electrode and a plurality of principal electrodes, means interconnecting said start valve and the control electrode and a principal electrode of said stop valve insuchmanner that said stop valve is rendered conductive in responseto said interconnecting means a predetermined interval of time after said` start valve is rendered conductive and meansinterconnecting said stop valve and said control electrode and a principal electrode of said control valve in such manner that said control valve is rendered non-conductive in response to said stop valve. 1

6. In combination a control electric discharge valve having a control electrode and a plurality of principal electrodes, a start electric discharge valve having a control electrode and a plurality of principal electrodes, a source of potential having a potential drop common to both said valves connected to impress a blocking potential between their respective control electrodes and one of their principal electrodes, means interconnecting said start valve and the control electrode and a principal electrode of said control valve for rendering said start valve and said control valve conductive, a stop electric discharge valve, means interconnecting said start valve and said stop valve for rendering said stop valve conductive a predetermined interval of time after said start valve is rendered conductive and means interconnecting said stop valve and said control valve in such manner that said control valve is rendered non-conductive in response to said stop valve.

7. In combination a control electric discharge valve -having a control electrode and a plurality of principal electrodes, a start electric discharge valve having a control electrode and a plurality of principal electrodes, asource or potential having a negative potential drop common to both said valves connected to impress a potential between their respective control electrodes and one of their principal electrodes to maintain said valves in a predetermined condition of excitation, means for changing the excitation of said start valve, means interconnecting said start valve and the control electrode and a principal electrode of said control valve in such manner that the excitation of said control valve is changed in response to said start valve, a stop electric discharge valve, means interconnecting said start valve and said stop valve in such manner that the excitation of C,said stop valve is changed in response to said interconnecting means a predetermined interval of time after the excitation of said start valve is changed and means interconnecting said stop valve and said control valve in such manner that thel excitation of said control valve islreverted to its original condition in response to the change in the excitation of said stop valve.

v8. The combination according to claim 5 characterized by the fact that the principal electrodes of the start and stop valves are connected in parallel circuits.

9. The combination according to claim 7 characterized by means interconnecting the start valve and the stop valve which includes a capacitor charged through said start valve and means for preventing substantial discharge of said capacitor through substantially any portion of the circuit aiecting the control valve.Y

l0. The combination according to claim 7 characterized by impedance means connected to 11. The combination according to claim 'lcharacterized by the fact that the principal electrodes of the start valve and the stop valves are in parallel circuit relation and bymeans interconnecting the start valve and the stop valve which includes a capacitor charged through said start valve and means for preventing substantial discharge oi said capacitorthrough substantially any portion of the circuit affecting the control valve.

12. In combination a control electric discharge` valve, a start electric discharge valve, means interconnecting said valves for rendering said start valve and said control valve conductive, a stop electric discharge valve having a control electrode and a plurality of principal electrodes, the principal electrodes of said stop valve being connected in parallel circuit relation with said start valve, and means interconnecting said start valve and the control electrode and a principal electrode of said stop valve in such manner that said stop valve is rendered conductive in response to said start valve a predetermined interval of time after said start valve, said interconnecting means between the start valve and the control electrode and principal electrode oi' the stop valve including a rectifier, a resistor, and a capacitor charged through said rectiiler and said resistor.

13. 1n combination a control electric discharge valve, a start electric discharge valve, means interconnecting said valves in such manner that said control valve is rendered conductive in response to said start valve when said start valve is rendered conductive, a source of potential having a positive terminal, an intermediate terminal and a negative terminal, the potential di!- !erence between the latter terminals being a substantial portion, of the order of V4 to V2, of the potential difference between the positive and negative terminals, a stop electric discharge valve having a control electrode and a plurality of principal electrodes, the principal electrodes of said stop valve beingfconnected in parallel circuit relation with said start valve, between said positive terminal and said intermediate terminal and said control electrode being connected to said negative terminal, and means interconnecting said start valve and the control electrode and a principal electrode of said stop valve in such manner that said stop valve is rendered conductive in response to said start valve a predetermined inteval of time after said start valve, said interconnecting means between the start valve and the control electrode and the principal electrode of the stop valve including a rectier, a resistor, and a capacitor charged through said rectiiler and said resistor, the potential impressed on the capacitor counter-balancing the potential supplied between the intermediate terminal and the negative terminal after a predetermined interval of time.

14. In a system for supplying current for discrete intervals of time to a load from a source of current the combination comprising a rst electric discharge valve means for controlling the ow of current from said source to said load, said rst valve means requiring biasing means, a second electric discharge'valve means coop- -erative with said first electric discharge valve means for initiating the flow of current from said source to said load, said second valve means requiring biasing means, a biasing means having a negative potential drop common to said first and second valve means, a third electric discharge valve means cooperative with said iirst means for interrupting the ilow of current from said squrce to said load a predetermined interval of time after it has been initiated, said third valve means requiring biasing means, and biasing means having a potential drop common to said nrst and third valve means.

FINN H. GULLIKSEN. 

